The manufacturing process of conductive cloth mainly includes the following key steps:
Raw material selection and pretreatment: The core material of conductive cloth is conductive fiber, which is mainly divided into two categories: metal fiber and carbon fiber. Metal fiber is mostly made of silver-plated copper alloy fiber with a diameter of 8-12 microns, which has the characteristics of stable conductivity and oxidation resistance; carbon fiber is made of modified polyacrylonitrile-based fiber with a diameter of 5-8 microns, which has the advantages of light weight and corrosion resistance. The base cloth usually uses high-strength polyester fiber or nylon fiber, and the yarn count is controlled between 40-60. After the raw materials enter the factory, they need to be treated with constant temperature and humidity for 48 hours to ensure that the moisture content of the fiber is stable between 8%-10%.
Weaving: The conductive fiber and the base cloth yarn are arranged in a ratio of 1:3 using a batch warping machine, the warping speed is controlled at 200-250 meters/minute, and the warp tension is maintained at 0.3-0.5 Newtons/tex. The rapier loom is used for double-layer weaving, with the upper layer being the conductive fiber interlaced layer and the lower layer being the base fabric support layer. When setting the loom parameters, the opening time is controlled at 290°-310°, and the weft beating force is set to 800-1000 N. During the weaving process, the uniformity of the conductive surface of the fabric is monitored in real time, and the surface resistance is tested with a non-contact resistance tester every half an hour, and the fluctuation range shall not exceed ±15%. Post-processing: The grey fabric after weaving needs to be processed by a continuous washing machine. The washing liquid uses a neutral detergent with a pH value of 6.5-7.5, and the water temperature is maintained at 60-70°C. After washing, it enters the hot air setting machine and is heat-set for 3-5 minutes at a temperature of 180-200°C to fully fuse the conductive fiber with the base fabric fiber. Subsequently, vacuum sputtering coating technology is used for secondary conductivity enhancement. The fabric is placed in a 10^-3 Pa vacuum environment, and a 50-100 nanometer thick indium tin oxide conductive layer is evenly deposited on the fabric surface through magnetron sputtering. The surface resistance of the treated fabric can be reduced.